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WO2025178486A1 - Récupération de polycarbonate à partir de déchets - Google Patents

Récupération de polycarbonate à partir de déchets

Info

Publication number
WO2025178486A1
WO2025178486A1 PCT/NL2025/050078 NL2025050078W WO2025178486A1 WO 2025178486 A1 WO2025178486 A1 WO 2025178486A1 NL 2025050078 W NL2025050078 W NL 2025050078W WO 2025178486 A1 WO2025178486 A1 WO 2025178486A1
Authority
WO
WIPO (PCT)
Prior art keywords
abs
polymer solution
solvent
fraction
previous
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
PCT/NL2025/050078
Other languages
English (en)
Inventor
Lucie PRINS
Lauran VAN GOLEN-KWAKERNAAT
Danny VAN KOL
Annemieke Van De Runstraat
Styrmir SVAVARSSON
Stephan Harkema
Cornelis Petrus Marcus Roelands
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Nederlandse Organisatie voor Toegepast Natuurwetenschappelijk Onderzoek TNO
Original Assignee
Nederlandse Organisatie voor Toegepast Natuurwetenschappelijk Onderzoek TNO
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Nederlandse Organisatie voor Toegepast Natuurwetenschappelijk Onderzoek TNO filed Critical Nederlandse Organisatie voor Toegepast Natuurwetenschappelijk Onderzoek TNO
Publication of WO2025178486A1 publication Critical patent/WO2025178486A1/fr
Pending legal-status Critical Current
Anticipated expiration legal-status Critical

Links

Classifications

    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J11/00—Recovery or working-up of waste materials
    • C08J11/04—Recovery or working-up of waste materials of polymers
    • C08J11/06—Recovery or working-up of waste materials of polymers without chemical reactions
    • C08J11/08—Recovery or working-up of waste materials of polymers without chemical reactions using selective solvents for polymer components
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J2355/00—Characterised by the use of homopolymers or copolymers, obtained by polymerisation reactions only involving carbon-to-carbon unsaturated bonds, not provided for in groups C08J2323/00 - C08J2353/00
    • C08J2355/02—Acrylonitrile-Butadiene-Styrene [ABS] polymers
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J2369/00—Characterised by the use of polycarbonates; Derivatives of polycarbonates
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02W—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
    • Y02W30/00—Technologies for solid waste management
    • Y02W30/50—Reuse, recycling or recovery technologies
    • Y02W30/62—Plastics recycling; Rubber recycling

Definitions

  • the invention is in the field of recycling plastic waste.
  • the invention is directed to a method to separate and fractionate polycarbonate from plastic waste.
  • the waste may be collected and sorted, wherein the sorting typically first comprises mechanical sorting by type of material (e.g. plastics, paper). Further downstream, the plastics are sorted by type of polymers, for instance by using infrared spectroscopy to obtain several mono streams.
  • a mono stream ideally comprises one type of polymer or a plurality of similar types of polymers, for instance PET (polyethylene terephthalate), which facilitates the repurposing of the polymer.
  • PC polycarbonate
  • PC polycarbonate
  • HIPS high impact polystyrene
  • This stream is particularly hard to recycle, as the manufacturing of new products often demands pure ABS, HIPS or PC (i.e. without additives) to make a blend with the desired mechanical properties.
  • Methods are known in the prior art to separate polymers in polymer mono streams.
  • WO 2022/255873 discloses a method to separate PC and a first-component such as ABS from plastic waste, based on nonselective dissolution and selective precipitation.
  • the present invention is directed to a method for at least partially separating and fractionating polycarbonate (PC) and acrylonitrile butadiene styrene (ABS) comprised in a plastic waste composition.
  • Fractionation herein means that different fractions of high purity PC are obtained, each having a different weight-average molecular weight of PC.
  • the method of the present invention comprises at least a dissolution stage and a PC fractionating stage.
  • the dissolution stage comprises contacting the plastic waste composition with a solvent to dissolve the PC and the ABS in said solvent in order to obtain a PC-rich polymer solution.
  • the PC fractionating stage comprises at least the following steps: - a first PC precipitation step comprising adding a weak anti-solvent in a first amount to the PC-rich polymer solution to precipitate part of the dissolved PC;
  • a first PC separation step comprising separating the PC precipitate obtained in the first PC precipitation step from the PC-rich polymer solution to obtain a first PC fraction and a second PC-rich polymer solution;
  • a second precipitation step comprising adding the weak anti-solvent in a second amount to the second PC-rich polymer solution to precipitate at least part of the remaining dissolved PC;
  • the method may further comprise an ABS recovery phase to recover the ABS from the PC-lean polymer solution.
  • Figure 1 illustrates a flow scheme of a preferred embodiment of the present invention.
  • the present invention is directed to a method for at least partially separating and fractionating polycarbonate (PC) and acrylonitrile butadiene styrene (ABS) comprised in a plastic waste composition.
  • the method of the present invention comprises at least a dissolution stage and a PC fractionating stage.
  • the dissolution stage comprises contacting the plastic waste composition with a solvent to dissolve the PC and the ABS in said solvent in order to obtain a PC-rich polymer solution.
  • the PC fractionating stage comprises at least the following steps: - a first PC precipitation step comprising adding a weak anti-solvent in a first amount to the PC-rich polymer solution to precipitate part of the dissolved PC;
  • a first PC separation step comprising separating the PC precipitate obtained in the first PC precipitation step from the PC-rich polymer solution to obtain a first PC fraction and a second PC-rich polymer solution;
  • a second PC separation step comprising separating the PC precipitate obtained in the second precipitation step from the second PC -rich polymer solution to obtain a second PC fraction and a PC-lean polymer solution.
  • Polymer blends can be broadly classified in three groups: immiscible polymer blends, compatible polymer blends and miscible polymer blends.
  • Immiscible polymer blends may also be referred to as heterogeneous polymer blends. The polymers in these blends typically form separate phases and their corresponding individual glass transition temperatures may be observed.
  • Compatible polymer blends are typically immiscible polymer blends that have macroscopically uniform physical properties due to sufficiently strong interactions between the polymers.
  • Miscible polymer blends may also be considered homogeneous polymer blends and typically have a single-phase structure for which one glass-transition temperature may be observed. This invention is particularly suitable for miscible polymer blends comprising at least PC and ABS.
  • the PC and ABS are dissolved in a solvent, which may be performed at an elevated temperature (i.e. above 20 °C).
  • a higher temperature typically accelerates the dissolution of the polymers.
  • the plastic waste composition is preferably contacted with the solvent in the dissolution stage at a temperature in the range of 60 °C to 250 °C, preferably in the range of 70 to 130 °C such as about 100 °C.
  • the dissolution may be performed at an elevated pressure to prevent boiling of the solvent. Accordingly, for example, the dissolution may be carried out at a pressure in the range of 1 to 10 bar, or higher.
  • the solvent is preferably selected from the group consisting of cyclopentanone, cyclohexanone and a combination thereof. It was surprisingly found that these solvents are particularly suitable to dissolve PC/ABS blends and may thus allow for separation with high purity and yields.
  • the method of the present invention allows for at least partially separating and fractionating PC and ABS from a solution comprising relatively high concentrations of PC and ABS.
  • the concentration of PC in the PC-rich polymer solution may be above 2 wt.%, preferably above 5 wt.%, more preferably above 7 wt.%.
  • the concentration of ABS in the PC-rich polymer solution may be above 1 wt.%, preferably above 2 wt.%.
  • the total concentration of PC and ABS polymer in the PC-rich polymer solution may be above 3 wt.%, preferably above 6 wt.%, more preferably above 8 wt.%, most preferably above 10 wt.%.
  • Being able to at least partially separate and fractionate PC and ABS from a solution comprising relatively high concentrations of PC and ABS is advantageous because it allows to apply the method of the present invention to plastic waste compositions comprising such relatively high concentrations of PC and ABS.
  • the plastic waste composition comprises, besides PC and ABS, further components, herein also referred to as impurities.
  • Impurities that are typically found in plastic waste include, for example, one or more of metals, minerals, pigments, dyes, paints, glass, and polymers such as polyethylene (PE), polymethyl methacrylate (PMMA) and polyethylene terephthalate (PET).
  • the solvent is preferably selected such that these impurities do essentially not dissolve in the solvent during the dissolution stage, such that they can be separated from the PC-rich polymer solution by solid/liquid separation techniques like filtrations.
  • the ABS comprises insoluble polybutadiene rubber (PBR) particles
  • PBR polybutadiene rubber
  • the PC-rich polymer solution obtained from the dissolution stage is a crude PC-rich polymer solution comprising impurities and the method further comprises a filtration stage following the dissolution stage, said filtration stage comprising filtering the crude PC-rich polymer solution to remove at least part of these impurities and to obtain a filtered PC-rich polymer solution which is proceeded to the PC fractionation stage.
  • the filtration stage preferably comprises clarification of the crude PC-rich polymer solution, such that this solution become clearer, i.e. more transparent to light.
  • This is advantageous when the method comprises light scattering to determining of the suitable amount of anti-solvent to be added (vide infra).
  • Light scattering is hampered by insoluble matter (i.e. matter that is not fully dissolved in the solvent) and as such, this matter is preferably substantially entirely removed in the filtration stage.
  • Substantially entirely herein means that at least 90 wt% of the impurities are removed.
  • undissolved matter may be entrapped in the precipitated PC and/or ABS in one of the later stages, thereby contaminating the recovered PC and/or ABS.
  • the non-soluble impurities are removed by filtration using a prepared filter bed comprising a filter and a filter aid.
  • a filter is typically sufficient to remove all of the non-soluble fraction and allows for the PC and/or ABS to remain in the filtrate.
  • Suitable filter aids include active carbon and/or diatomaceous earth such as Celite®.
  • filter aids may capture impurities such as pigments, dyes, paints, etc., but also short-chained polycarbonates (despite the fact that the pores are sufficiently large for them to pass through) thereby improving the purity and poly dispersity of the fractions.
  • the filter aids may accordingly assist in decoloring the solution, as well as in improving the purification.
  • the present method enables the recovery of PC fractions with different molecular weights by sequential precipitation and separation with increasing amounts of anti-solvent. Surprisingly, this is not negatively influenced by the presence of ABS and/or HIPS.
  • weak anti-solvent is herein used to indicate that it is an anti-solvent that in principle only allows PC to precipitate out of the polymer solution. It is well-known in the art that the addition of an antisolvent can enhance the precipitation of a solute. The anti-solvent typically decreases the solubility of the solute and thus the solute is driven towards precipitating out of the polymer solution.
  • suitable weak antisolvents are lower ketones such as acetone, MIBK and methyl ethyl ketone (MEK).
  • the term “lower”, regarding the ketones, refers to the molecular weight of said ketones, which is preferably less than 200 g/mol, more preferably less than 150 g/mol.
  • the PC precipitate is separated from the remainder of the polymer solution to obtain a PC-rich fraction and a second PC-rich solution.
  • the second PC-rich solution still contains PC, but less than the PC-rich polymer solution that entered to fractionation phase.
  • a further amount of weak anti-solvent is added to the second PC-rich solution to precipitate at least part of the remaining dissolved PC.
  • the PC precipitate obtained in the second precipitation step from the second PC-rich polymer solution to obtain a second PC fraction and a PC-lean polymer solution.
  • the fractionation stage comprises at least two precipitation and separations steps, but may contain additional precipitation and separations steps to obtained further PC fractions.
  • Each of these additional precipitation and separation steps individually comprise adding the weak anti-solvent in a particular amount and subsequently separating the precipitated PC.
  • the amount of anti-solvent to be added in each precipitation step is influenced by the concentration of PC in the respective PC-rich polymer solution, the molecular weights of the PC polymeric molecules in solution, the amount of ABS, impurities, and the hke. This may differ for each plastic waste composition batch.
  • a suitable way to add an appropriate amount of weak anti-solvent comprises adding the weak anti-solvent while monitoring the PC-rich polymer solution for the occurrence of precipitation. Once initiation of precipitation is observed, addition of the weak anti-solvent can be ceased for that particular step. Monitoring can be carried out by eye, but also by techniques that allow automation such as optical sensing including light scattering and/or infra-red analysis, viscosity measurements, and the like.
  • Each precipitation step of the PC typically leads to the precipitates such as flakes and may be considered a solid or slurry.
  • the PC is recovered by separation, for instance by substantially removing the solvent and the weak anti-solvent.
  • the solvent and weak anti-solvent may be removed down to approximately 1-2% based on the total weight of the PC fraction. Removal thereof can be achieved by any means known in the art, such as evaporation or lyophilization.
  • the recovered PC may be processed further by for instance vacuum kneading, typically rendering the solvent and weak anti-solvent content to 0.1% or lower.
  • the first PC fraction comprises the PC with the highest weightaverage molecular weight.
  • the weight-average molecular weight of the further fractions decrease with each fraction that is provided.
  • the PC in the first PC fraction has a higher weight-average molecular weight than the PC in the second PC fraction.
  • the PD index of the fraction inter alia depend on the total number of fractions that are produced. More factions lead to lower PD indices.
  • the PD index of the first PC fraction typically has a polydispersity (PD) index in the range of at most 3, preferably at most 2.5, most preferably at most 2.
  • the PD index herein means the measure of the degree of the molecular weight distribution (MWD) of the polymer and is defined as Mw divided by Mn, where Mw is the weight- average molecular weight and Mn is the number-average molecular weight.
  • This PC-lean polymer solution at least still comprises the dissolved ABS. This ABS can be recovered in the subsequent ABS recovery phase.
  • the ABS recovery phase is preferably carried out.
  • the PC-lean polymer solution may contain the compounds ABS (typically E- ABS), SAN and polybutadiene, a combination thereof, SAN without polybutadiene or a combination of ABS and SAN without polybutadiene.
  • ABS in the ABS recovery phase refers to all these compounds.
  • the recovered SAN can be recompounded with addition of virgin polybutadiene rubber to form ABS in a subsequent, separate, process.
  • strong anti-solvent is herein used to describe an anti-solvent that is capable of enhancing the precipitation of the ABS.
  • the strong anti-solvent can be selected from a variety of solvents.
  • the strong anti-solvent comprises lower ketones such as acetone and/or lower alcohols such as methanol, ethanol and/or propanol.
  • the strong anti-solvent comprises methanol and/or acetone.
  • the solvent, weak and/or strong antisolvent can be identical.
  • the function of the particular fluid i.e. solvent, anti-solvents
  • the specific combination of e.g. a solvent and a weak anti-solvent may alter the environment in such a manner that the affinity for the solution and the solubility of the ABS changes.
  • Adding an amount of strong anti-solvent, e.g. an identical fluid to the weak anti-solvent may then cause the ABS to precipitate, although this may not be the case while adding the first amount of the fluid as the weak anti-solvent.
  • the function of the fluid may also depend on the amount of fluid used.
  • a strong anti-solvent may thus function as a weak anti-solvent if dosed in a smaller amount.
  • the method according to the present invention may further comprise separating the ABS precipitate from the PC-lean polymer solution to obtain an ABS fraction and a residue solution.
  • This residue solution may comprise the solvent and the strong anti-solvent.
  • the residue solution may comprise the weak anti-solvent.
  • the weak antisolvent may be at least substantially removed from the PC-lean polymer solution before the addition of the strong anti-solvent. Removal of the weak anti-solvent before adding the strong anti-solvent may be favorable as this typically entails the separation of two liquids (i.e. the solvent and weak antisolvent), which is a relatively minimal complex mixture.
  • the solvent, strong anti-solvent and/or weak anti-solvent may be separated from the residue solution, polycarbonate rich fraction and/or first-component rich fraction.
  • This separation is preferably to the extent that each of the solvent, weak antisolvent and/or strong anti-solvent may be recovered as individual streams that are suitable to be reused in the method.
  • the separation and recovery may for instance be by distillation.
  • the solvent may be recovered with a sufficiently high purity in order to be reused as solvent.
  • some impurities from e.g. anti-solvents are allowed, however the amount thereof should not compromise its function as solvent.
  • This solution 5 is continued in the second PC precipitation step (14), wherein the second amount of weak anti-solvent (22) is added to solution 5.
  • This leads to further precipitation of PC giving the second PC precipitate (6) in suspension which is subsequently subjected to the second PC separation step (15) to separate the second PC fraction (32) from the PC-lean polymer solution (7).
  • This polymer solution 7 is continued in the ABS recovery stage, starting with addition of the strong anti-solvent (23) to precipitate at least part of the ABS in the ABS precipitation step (16) and giving a ABS precipitate (8) in suspension.
  • the ABS fraction (33) can be obtained in an ABS separation step (17), to separate the ABS precipitation from the residue solution (34).
  • the polymer solution was precipitated by addition of ethanol. The precipitation was done sequentially using at first 80 ml of ethanol and followed with 30 ml increments. After each ethanol addition, the polymer solution was stirred for an hour and filtered through paper filter. Any precipitated polymer was collected and the recovered polymer solution further precipitated. Whole process was repeated until four fractions were collected. For the last fraction (no. 5), an excess of ethanol (200ml) was added to recover any PC still left in the solution. All recovered fractions were dried overnight in the vacuum oven at 40 °C and weighed. The products were analyzed by FTIR and consistent with PC.
  • An IMSE device no. 2 was used for the experiment aiming at PC recovery from the multicomponent sample, i.e. various types of PC, ABS, inks, and other materials.
  • the device as analyzed by FTIR prior the dissolution experiment to verify its composition. FTIR analysis showed that both PC and ABS are present in the device.
  • the device was placed in a container and dissolved in cyclopentanone at 100 °C.
  • the device was not fully submerged at the beginning of the dissolution but as the dissolution process progressed, all polymer parts were eventually in contact with the solvent and got dissolved. Only the metal part from inside the device remained undissolved, which was removed by solid/liquid separation.

Landscapes

  • Chemical & Material Sciences (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Sustainable Development (AREA)
  • Health & Medical Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Medicinal Chemistry (AREA)
  • Polymers & Plastics (AREA)
  • Organic Chemistry (AREA)
  • Separation, Recovery Or Treatment Of Waste Materials Containing Plastics (AREA)
  • Addition Polymer Or Copolymer, Post-Treatments, Or Chemical Modifications (AREA)

Abstract

L'invention concerne un procédé de séparation et de fractionnement au moins partiel de polycarbonate (PC) et d'acrylonitrile butadiène styrène (ABS) compris dans une composition de déchets plastiques, ledit procédé comprenant au moins une étape de dissolution et une étape de fractionnement de PC, l'étape de dissolution comprenant la mise en contact de la composition de déchets plastiques avec un solvant pour dissoudre le PC et l'ABS dans ledit solvant pour obtenir une solution de polymère riche en PC ; et l'étape de fractionnement de PC comprenant le fractionnement du PC pour fournir au moins une première fraction de PC et une seconde fraction de PC qui ont des distributions de poids moléculaire différentes.
PCT/NL2025/050078 2024-02-19 2025-02-19 Récupération de polycarbonate à partir de déchets Pending WO2025178486A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
EP24158331.9A EP4603531A1 (fr) 2024-02-19 2024-02-19 Récupération de polycarbonate à partir de déchets
EP24158331.9 2024-02-19

Publications (1)

Publication Number Publication Date
WO2025178486A1 true WO2025178486A1 (fr) 2025-08-28

Family

ID=89984563

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/NL2025/050078 Pending WO2025178486A1 (fr) 2024-02-19 2025-02-19 Récupération de polycarbonate à partir de déchets

Country Status (2)

Country Link
EP (1) EP4603531A1 (fr)
WO (1) WO2025178486A1 (fr)

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0448082A2 (fr) 1990-03-22 1991-09-25 ENICHEM S.p.A. Méthode et appareil pour le fractionnement en continu de polymères
WO2006030020A1 (fr) 2004-09-17 2006-03-23 Solvay (Société Anonyme) Procede de traitement de melange abs/ps
WO2015076868A1 (fr) * 2013-11-19 2015-05-28 Purdue Research Foundation Procédés utiles pour récupérer des polymères à partir de déchets électroniques et autres
EP4098688A1 (fr) * 2021-06-01 2022-12-07 Nederlandse Organisatie Voor Toegepast- Natuurwetenschappelijk Onderzoek Tno Séparation efficace de polycarbonate d'un mélange de matières plastiques

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0448082A2 (fr) 1990-03-22 1991-09-25 ENICHEM S.p.A. Méthode et appareil pour le fractionnement en continu de polymères
US5185429A (en) * 1990-03-22 1993-02-09 Istituto Guido Donegani S.P.A. Procedure for the continuous fractionation of polymers and relative equipment
WO2006030020A1 (fr) 2004-09-17 2006-03-23 Solvay (Société Anonyme) Procede de traitement de melange abs/ps
WO2015076868A1 (fr) * 2013-11-19 2015-05-28 Purdue Research Foundation Procédés utiles pour récupérer des polymères à partir de déchets électroniques et autres
EP4098688A1 (fr) * 2021-06-01 2022-12-07 Nederlandse Organisatie Voor Toegepast- Natuurwetenschappelijk Onderzoek Tno Séparation efficace de polycarbonate d'un mélange de matières plastiques
WO2022255873A1 (fr) 2021-06-01 2022-12-08 Nederlandse Organisatie Voor Toegepast-Natuurwetenschappelijk Onderzoek Tno Séparation efficace de polycarbonate à partir de matières plastiques mélangées

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